Discovery Faults

Hi,

A few months ago, I bought a Q-reg LR Disco 2.5 Tdi. I think it's a
1992 model. A great all-rounder, it's already a firm favourite with
the family. However, it's got 2 faults which I'm wondering if anyone
can shed any light on.

1. The hydraulic clutch loses fluid but I can't find the leak. If I
don't top it up with fluid every 3 weeks or so the gears start
crunching and eventually I get a completely slack pedal (as soon as I
do top it up, the clutch returns to normal). It's all very peculiar -
I've had the slave and the master cylinder replaced but the problem
remains. It's cheap enough to keep topping it up, I suppose, but I was
wondering if this was a common fault and if someone might know the
cause/cure.

2. The ignition switch has now started playing up and has recently
started cutting the engine out whilst the car is on the road - which is
a bit hairy! Initially, the car intermittently wouldn't start and I
narrowed the problem down to the ignition switch. I took the switch
apart and cleaned it and that cured it for a short while, but now the 2
parts of the switch unit won't nip together properly and I have to
gently wiggle the whole unit as I start the car, or it just cuts out.
Again, is this a common fault and is there a simple cure or do I have
to buy a new ignition switch? (If so, I'd appreciate any tips on decent
suppliers).

Thanks for any help.

- Tom Bennett

On 1 Oct 2005 13:28:27 -0700, [email protected] wrote:

>A few months ago, I bought a Q-reg LR Disco 2.5 Tdi

Why is it on a Q plate?

It's a UK car but it's had a chequered history: The car was stolen and
the engine and gearbox were pinched (a good few years ago, I believe).

When it was recovered and a new engine was fitted, it had to go on a
"Q" plate because it was now of mixed pedigree. Or, again, so I was
told.

I've become very attached to the old girl but I'm afraid she isn't
worth spending a fortune on anymore. But I keep having the odd minor
triumph with my very limited and equally rusty motor repair skills -
such as getting the aircon working again when I bought her - by the
simple step of renewing the blown fuse.

- Tom.

Tom

not familiar with the Manual disco (I have an auto) but I can think of
two possible causes for the loss of fluid that you haven't found.

If the clutch system shares it's fluid reservoir with the brake master
cylinder - the plastic tank on the top of the brake master cylinder -
you may be loosing fluid via the brake system. If the reservoir is
shared please investigate further as no brakes is a lot more important
than no clutch. If it isn't shared then disregard this option. (Just
checked my Range Rover workshop manual which I use to maintain the
Disco with and it looks like the reservoir is separate

The other place you may find fluid is in the carpet behind/under the
clutch pedal due to master cylinder seal leakage. New ones don't always
work perfectly.

Jon in NZ

In message <[email protected]>,
[email protected] writes
>1. The hydraulic clutch loses fluid but I can't find the leak. If I
>don't top it up with fluid every 3 weeks or so the gears start
>crunching and eventually I get a completely slack pedal (as soon as I
>do top it up, the clutch returns to normal). It's all very peculiar -
>I've had the slave and the master cylinder replaced but the problem
>remains. It's cheap enough to keep topping it up, I suppose, but I was
>wondering if this was a common fault and if someone might know the
>cause/cure.
>


The clutch system should be fitted with a damper unit which is a metal
disc shaped device that the fluid passes through on the way to the
slave cylinder. It is bolted to the bracket with the slave cylinder you
can't miss it. These will loose fluid slowly like you describe. Only
cure is to replace or remove from circuit ( you will need to mess with
pipes if you want to remove it) It is s'posed to stop the pedal from
pulsing from the effect of the clutch fingers on the release bearing
when the clutch is pressed. So not really needed.


>2. The ignition switch has now started playing up and has recently
>started cutting the engine out whilst the car is on the road - which is
>a bit hairy! Initially, the car intermittently wouldn't start and I
>narrowed the problem down to the ignition switch. I took the switch
>apart and cleaned it and that cured it for a short while, but now the 2
>parts of the switch unit won't nip together properly and I have to
>gently wiggle the whole unit as I start the car, or it just cuts out.
>Again, is this a common fault and is there a simple cure or do I have
>to buy a new ignition switch? (If so, I'd appreciate any tips on decent
>suppliers).


Not really a common problem.

Fit a new one.

Good luck
--
Marc Draper

Thanks to the group for all your help:

To Jon, the clutch is separate to the brakes and there's no fluid to be
seen on the carpet. I'll investigate as per Marc's suggestion at the
weekend.

I've "cured" the ignition switch by wrapping stiff wire between the end
cap and the main body of the switch and then twisting the wire tight.
This has brought the two sections firmly together and is, so far, (I
did it 2 days ago) working fine.

Thanks again

Regards,

- Tom Bennett

Tom

not familiar with the Manual disco (I have an auto) but I can think of
two possible causes for the loss of fluid that you haven't found.

If the clutch system shares it's fluid reservoir with the brake master
cylinder - the plastic tank on the top of the brake master cylinder -
you may be loosing fluid via the brake system. If the reservoir is
shared please investigate further as no brakes is a lot more important
than no clutch. If it isn't shared then disregard this option. (Just
checked my Range Rover workshop manual which I use to maintain the
Disco with and it looks like the reservoir is separate

The other place you may find fluid is in the carpet behind/under the
clutch pedal due to master cylinder seal leakage. New ones don't always
work perfectly.

Jon in NZ